EP2167754B1

EP2167754B1 - Construction panel

Info

Publication number: EP2167754B1
Application number: EP08748280.8A
Authority: EP
Inventors: Antonio Rapaz
Original assignee: Individual
Current assignee: Individual
Priority date: 2007-05-09
Filing date: 2008-05-09
Publication date: 2017-02-22
Anticipated expiration: 2028-05-09
Also published as: EP2167754A4; CA2690248C; CA2690248A1; US8464490B2; US20080276567A1; EP2167754A1; WO2008138116A1

Description

Related Application

The application is a continuation-in-part of US patent application serial No. 11/746,301 filed 9 May 2007 .

Technical Field

This application relates to a multi-purpose construction panel.

Background

Modular panels may be used for many different types of construction applications. For example, interlocking panels may be used to form temporary flooring, roofing or wall structures. Other potential commercial applications are described in applicant's co-pending US patent application, serial No. 11/689,409 filed 21 March 2007 entitled MULTI-PURPOSE CONSTRUCTION MODULE.
Patent publication WO 2005/081923 A2 relates to an interlocking modular floor tile. The floor tile includes a plurality of support legs or male connectors positioned within the perimeter of the tile and a plurality of interlocking female connectors which are positioned on two sides at the perimeter of the tile. Adjacent tiles may be coupled together by inserting some of the male connectors of one tile into the female connectors of an adjacent tile. The male connectors and a supporting grid extend on one side of the tile and are ground-engaging in order to provide vertical support to the tile. Multiple tiles are intended to be aligned adjacent one another in a common plane.
Patent publication WO 99/36638 A1 relates to a decking tile for supporting decking slats. Adjacent tiles can be connected together by bringing first and second components located on sides of each tile together in an interlaced manner. Thus any side of one tile can be connected to any other side of an adjacent tile. Wooden slats are placed on an upper surface of the tile and may be secured to the tile with fasteners. Thus, like the floor tile of WO 2005/081923 A2 , the tiles of WO 99/36638 A1 are intended to be aligned adjacent one another in a common plane.
There is a need for light-weight, economical construction panels particularly suitable for sale directly to consumers at building supply retail outlets and the like. There is a particular need for construction panels which may be quickly and easily coupled together without the need for specialized tools or skills to form a wide variety of construction assemblies.

Summary of Invention

In accordance with the invention, a construction panel having a first side and a second side is provided. The first side comprises a substantially planar deck and the second side comprises a plurality of first wall elements defining a plurality of compartments therebetween and a plurality of sleeves each located in one of the compartments. The sleeves include a first group of female sleeves having a first height and a second group of male sleeves having a second height exceeding the first height, wherein the male sleeves of one of the panels are sized to fit within the female sleeves of another one of the panels (i.e. when a pair of panels are coupled together with their respective second sides facing inwardly). The male and female sleeves are arranged in an alternating array within the compartments.
In one embodiment, at least some of the wall elements may include notches formed on an edge portion thereof. When a pair of panels are coupled together to form a construction assembly, the notches together define a conduit extending through the interior of the assembly. A fluid delivery tube may be deployed within a conduit for circulating fluid through the assembly, such as heated air or water for regulating the temperature or other physical characteristics of the assembly.
The invention comprises both single construction panels and construction assemblies formed from two or more panels.

Brief Description of Drawings

In drawings which describe embodiments of the invention but which should not be construed as restricting,

Figure 1 is an exploded, isometric view of two mating construction panels configured in accordance with the invention.
Figure 2 is an isometric view of the construction panels of Figure 1 in an assembled configuration.
Figure 3 is an exploded, isometric view of multiple bottom construction panels aligned adjacent one another and showing a single top panel.
Figure 4 is an isometric view of the assembly of Figure 3 showing the panels assembled together with the top panel in an overlapping orientation.
Figure 5 is an isometric view similar to Figure 4 showing multiple top panels.
Figure 6 is an isometric view similar to Figure 4 showing multiple top and bottom panels coupled together.
Figure 7 is an exploded, isometric view similar to Figure 3 showing the bottom panels arranged in an elongated pattern and showing a single top panel.
Figure 8 is an isometric view of the assembly of Figure 7 showing the panels assembled together with the top panel in longitudinal alignment with the bottom panels.
Figure 9 is an isometric view similar to Figure 8 showing two top panels.
Figure 10(a) is an isometric view of an assembly comprising multiple construction panels coupled together and showing fluid delivery tubes extending through conduits defined within the interior of the assembly.
Figure 10(b) is an isometric view of the assembly of Figure 10(a) showing the fluid delivery tubes in a different direction.
Figure 11 is a plan view of a first surface of a single construction panel.
Figure 12 is a plan view of a second surface of a construction panel.
Figure 13(a) is a first end elevational view of the panel.
Figure 13(b) is a second end elevational view of the panel.
Figure 14(a) is a first side elevational view of the panel.
Figure 14(b) is a second side end elevational view of the panel.
Figure 15 is an exploded, end isometric view of two mating construction panels configured in accordance with the invention.
Figure 16 is an isometric view showing the first surface of a single construction panel.
Figure 17 is an isometric view showing the second surface of a single construction panel.
Figure 18 is an enlarged, top plan view of the first surface of the panel similar to Figure 11.
Figure 19 is an enlarged, top plan view of a second surface of the panel similar to Figure 12.
Figure 20(a) is a first side elevational view of a single panel.
Figure 20(b) is a second side elevational view of a modified embodiment of the panel.
Figure 21(a) is a first end elevational view of single panel.
Figure 21(b) is a second end elevational view of a single panel.
Figure 22 is an exploded, end isometric view of two mating construction panels configured in accordance with an alternative embodiment the invention.
Figure 23 is an isometric view showing the first surface of a single construction panel of Figure 22.
Figure 24 is an isometric view showing the second surface of a single construction panel of Figure 22.
Figure 25 is an enlarged, top plan view of the first surface of the panel of Figure 22.
Figure 26 is an enlarged, top plan view of a second surface of the panel of Figure 22.

Description

Throughout the following description, specific details are set forth in order to provide a more thorough understanding of the invention. However, the invention may be practiced without these particulars. In other instances, well known elements have not been shown or described in detail to avoid unnecessarily obscuring the invention. Accordingly, the specification and drawings are to be regarded in an illustrative, rather than a restrictive, sense.
This application relates to a multi-purpose construction panel 10. In the illustrated embodiment panel 10 is generally rectangular in shape. As shown in Figures 1 and 2, each panel 10 may be matingly engaged with another panel 10 to form an assembly 12. As shown in Figures 3 - 9, and as described in further detail below, a plurality of panels 10 may be aligned in a desired configuration and releasably coupled together to form assemblies 12 of different sizes and shapes.
Each panel 10 has a first side 14 and a second side 16. As shown in Figures 11 and 18, for example, first side 14 may comprise a planar deck surface 18 interrupted by a plurality of channels 20. Optionally, a plurality of small apertures 22, which extend between sides 14,16, may be spaced within channels 20. The orientation of the channels 20 may be arranged to form a decorative pattern on first side 14. For example, channels 20 may subdivide deck surface 18 into a plurality of quadrilateral or triangular shaped deck segments. In alterative embodiments, side 14 may consist of a flat continuous sheet or other shapes or patterns could be substituted.
Panel second side 16 is subdivided into a plurality of compartments 24 by wall partitions 26, as shown in Figures 12,17 and 19 for example. In the illustrated embodiments, compartments 24 are square or rectangular in shape. A plurality of cylindrical female sleeves 28 and male sleeves 30 are disposed within compartments 24. In the illustrated embodiment male sleeves 30 have a smaller diameter and larger height than female sleeves 28. More particularly, sleeves 30 project from compartments 24 to a greater extent than sleeves 28. When a pair of panels 10 are coupled together as shown in Figure 2, the second sides of the respective panels 10 matingly engage such that each male sleeve 30 on one panel 10 is received within a corresponding female sleeve 28 on the other panel 10, and vice versa.
As best shown in Figures 12,17 and 19, each compartment 24 may be further subdivided by wall partitions 32 into subcompartments 34. In the illustrated embodiment each compartment 24 is divided into 4 subcompartments 34. Each wall partition 32 is connected to and structurally supports a sleeve 28, 30. A small cylindrical guide tube 36 may be disposed within each subcompartment 34. Each tube 36 may be connected to a corresponding sleeve 28, 30 by means of a flange 38. As described further below, tubes 36 may function as guides for receiving fasteners used to couple mating panels 10 together. As described below, the fasteners (not shown), are insertable into tubes 36 through apertures 22 which are aligned therewith.
The bottom or innermost surface 40 of panel second side 16 is generally flat. However, as best shown in Figure 17 and 19, surface 40 may comprise elongated ribs 42 which define the channels 20 of panel first side 14, as described above.
As shown, for example, in Figure 15, some wall partitions 26 and 32 comprise linearly aligned notches 44 formed in edge portions thereof. In the illustrated embodiment, each notch 44 has a semi-circular or quarter-circular profile. As shown best in the end elevational views of Figures 13(a),(b) and 21(a), (b), wall partitions 26 and 32 having notches 44 with a quarter-circular profile may be located at the edges of panel 10 (i.e. where a panel 10 may be arranged to abut another panel 10). When a mating pair of panels 10 are coupled together to form an assembly 12 with the second side 16 of each panel facing inwardly, the notches 44 of each panel 10 are aligned and together define a cylindrical conduit 46 extending through the interior of assembly 12 (Figure 2). Likewise, when four or more panels 10 are grouped together to form larger structures, conduits 46 may be defined at the joinder between adjacent pairs of assemblies (Figure 10(a) and 10(b)). As shown in Figure 10(a), each conduit 46 may receive a fluid delivery tube 48, for example for circulating anti-freeze, heated air or other fluid through each assembly 12. Other filaments may also be disposed in conduits 46, such as cables for use in securing a large number of assemblies 12 together. Optionally, as shown in Figure 10(b), tubes 48 or other filaments may be deployed in each assembly 12 in a transverse rather than longitudinal direction (that is, tubes 48 may extend in a direction perpendicular to the direction shown in Figure 10(a)).
A plurality of construction panels 10 may be conveniently coupled together to form assemblies 12 having many different possible shapes and sizes. As shown in Figures 3 - 9, multiple panels 10 forming a base portion may first be aligned adjacent one another, each with their first side 14 facing downwardly on a support surface and their second side 16 facing upwardly. A plurality of mating panels 10 forming a top portion, each with their second side facing downwardly and their first side facing upwardly, may then be placed on the aligned base panels 10. As shown in Figures 3 - 6, each top panel 10 may be positioned so that it overlaps multiple base panels 10 to bind the base panels 10 together. Alternatively, each top panel 10 may be positioned so that it is aligned with only a single corresponding base panel 10, as shown in Figures 2, 10(a), 10(b) and 15.
As will be appreciated by a person skilled in the art, although the terms "base" and "top" have been used in the example above, assembly 12 may be configured in many different orientations. For example, since each panel 10 of assembly 12 is identical in this embodiment, and hence assembly 12 is symmetrical, assembly 12 may be flipped 180 degrees so that the "top" panels form part of the base and vice versa. Further, assemblies 12 may be oriented vertically, for example as part of a wall structure, or in other non-horizontal orientations.
Once panels 10 have been assembled as desired to form assembly 12, panels 10 may be secured together with fasteners. For example, bolts (not shown) may be inserted through selected apertures 22 on one side of assembly 12 and into tubes 36. Once they are fully inserted, bolts may be secured, such as with nuts, on the opposite side of assembly 12.
In some applications it may be desirable that assembly 12 be fluid-impervious. For example, in chemical warehouses and the like it may be important that flooring be impervious to fluid chemicals to prevent soil and groundwater contamination. In such applications, grooves 20 on panel first surfaces 14 may be filled with caulking or other
sealants after panels 10 have been fastened together. In other embodiments, panels 10 may be manufactured with no apertures 22 or with only a small number of apertures 22 necessary to secure panels 10 together. This would avoid the need to seal unfilled apertures 22.
In other applications, it may be important that a large number of apertures 22 remain open after assembly 12 is assembled and deployed. For example, assembly 12 may be used in applications, such as temporary walkways, where it is desirable to avoid collection of water
on the surface thereof. In such applications water can be collected within channels 20 and drain through tubes 36 into the ground or other support surface underlying assembly 12. Apertures 22 also enable any water or water vapour within the interior of assembly 12 to escape to the surrounding environment. This may be important in northern climates
having frequent freeze/thaw weather cycles.
Construction panels 10 may be formed from molded plastic or other light-weight materials in one embodiment of the invention. By way of non-limiting example, each panel 10 may be 81.28 X 121.92 cm (32" X 48") in size have a thickness of approximately 5.08 cm (2"). In this example, each compartment 24 is approximately 20.32 X 20.32 cm (8" X 8") in size and each longitudinally extending conduit 46 (Figure 10(a)) is approximately 40.64 cm (16") apart. A plastic panel 10 having the above dimensions weighs on the order of about 9.07 kg (20 pounds) and may therefore be easily lifted and carried by a single person for ease of installation. This enables convenient assembly or disassembly of panels 10 by ordinary consumers without the need for cranes or other heavy lifting machinery.
Construction panels 10 may be used to form assemblies 12 useful in a wide variety of applications. For example, assemblies 12 may be used in flooring, roofing and wall construction applications in both indoor and outdoor environments. By way of non-limiting examples, assemblies 12 may be used in walkways, roadways, parking lots, driveways, decking and roofing. In some applications, assemblies 12 may be mounted on top of existing structures, such as decking joists or beams, or may be covered by other materials, such as roofing materials. Since panels 10 are lightweight and easy to handle, and relatively inexpensive to manufacture and transport, they will be useful in many consumer applications. Other potential consumer and industrial applications for construction panels and the like are described in the applicant's co-pending US application serial No. 11/689,409 filed 21 March 2007 entitled MULTI-PURPOSE CONSTRUCTION MODULE.
As described above, assemblies 12 may be deployed in applications where it is desirable to regulate the temperature or other physical characteristics thereof. For example, heated assemblies 12 may be used as temporary driveway covers in winter months to prevent snow and ice accumulation. The temperature of assemblies 12 may be regulated by circulating fluids in a flow path through the interior of each assembly 12. For example, as shown schematically in Figure 10, in one embodiment of the invention a heat-regulating or heat exchanging fluid may be circulated through tubing 48 deployed within conduits 46. As used in this patent application, the term "fluids" includes both liquids and gases. For example, the fluid may be water heated by a boiler (not shown) in fluid communication with tubing 48. In another embodiment of the invention, the fluid may be anti-freeze. In yet another embodiment, gases could be circulated within conduits 46, such as heated air. The boiler may include a fluid pump or, alternatively, a pump may be installed at another location in the flow path As is well known in the prior art, the fluid pump may include a timer or other controller to operate only during selected intervals rather than continuously.
By way of further example, assemblies 12 may be connected to form panels suitable for use as heated flooring, roofing or wall panels. For example, heated flooring, walls or roofing comprising construction panels 10 could be used in barns, stables, greenhouses, storage sheds or other temporary structures where it is important to control indoor temperature or avoid snowfall or ice accumulation. As indicated above, other materials could be placed over assemblies 12 such as dirt, mulch, bedding, rubber matting, styrofoam or other roofing materials, depending upon the particular application.
As indicated above, assemblies 12 could be temporarily installed in outdoor parking lots, driveways, roadways and the like to melt snow during winter months in northern climates. Assemblies 12 could similarly used on roofing to reduce or prevent snow accumulation. Assemblies 12 could be configured so that they are heated only during particular climatic conditions or during particular times of day. At the end of the winter season the panels 12 could be quickly and easily disassembled and removed if desired.
Depending upon the application and range of operating temperatures, the distance between conduits 46 could be adjusted. For example, in very cold conditions the number of conduits 46 carrying heated water in tubes 48 could be increased to reduce the distance between adjacent conduits and ensure that the entire assembly 12 is evenly heated. As will be appreciated by a person skilled in the art, in alternative embodiments of the invention the flow path of conduits 48 could also be varied (e.g. by using non-linear flow paths) to achieve substantially even heating or to suit particular applications.
As will be appreciated by a person skilled in the art, construction panels 10 may be formed in many different shapes and sizes. For example, in addition to rectangular shapes, panels 10 could be constructed in hexagonal, pentagonal or other geometric shapes or combinations thereof.
A further embodiment of the invention is in Figures 22-26. In this embodiment a tube 36a may be located in each sleeve 28 and 30. As described above, panels 10 may be coupled together to form an assembly 12 with each male sleeve 30 inserted into a corresponding female sleeve 28. Panels 10 may then be secured together with fasteners such as bolts inserted through selected apertures 22 on one side of assembly 12 and into tubes 36a (instead of, or in addition to, tubes 36). Once they are fully inserted, bolts may be secured, such as with nuts, on the opposite side of assembly 12. Each panel may also include notches 22a surrounding an aperture 22 on first side 14 to accommodate a bolt head, nut or washer. This ensures that end portions of the fastener will be flush or recessed relative to deck 18.
In the embodiment of Figures 22-26 additional flanges 38 may be provided for structurally supporting tubes 36 and 36a. For example, as shown best in Figure 26, each tube 36, 36a may be supported by four separate flanges 38.
As will be apparent to those skilled in the art in the light of the foregoing disclosure, many alterations and modifications are possible in the practice of this invention without departing from the scope thereof. Accordingly, the scope of the invention is to be construed in accordance with the substance defined by the following claims.

Claims

A construction panel (10) having a first side (14) and a second side (16), wherein said first side (10) comprises a substantially planar deck (18) and said second side (16) comprises:
(a) a plurality of first wall elements (26) defining a plurality of compartments (24) therebetween; and

(b) a plurality of sleeves (28, 30), wherein
said sleeves (28, 30) comprise a first group of female sleeves (28) having a first height and a second group of male sleeves (30) having a second height exceeding said first height, wherein said male sleeves (30) of one of said panels (10) are sized to fit within said female sleeves (28) of another one of said panels (10), characterized in that each sleeve (28, 30) is located in one of said compartments (24) and that said female and male sleeves (28, 30) are arranged within said compartments (24) in an alternating array.
The panel (10) as defined in claim 1, wherein said deck (18) has a plurality of spaced-apart channels (20) formed therein.
The panel (10) as defined in claim 2, wherein said channels (20) subdivide said deck (18) into a plurality of quadrilateral or triangular shaped deck segments.
The panel (10) as defined in claim 2, comprising a plurality of spaced-apart apertures (22) extending through said panel (10) between said first and second sides (14, 16).
The panel (10) as defined in claim 4, wherein said apertures (22) are located in said channels (20).
The panel (10) as defined in claim 1, wherein said sleeves (28, 30) are cylinders each having an open end at a location furthest from said deck (18).
The panel (10) as defined in claim 6, wherein said female sleeves (28) have a diameter exceeding a diameter of said male sleeves (30).
The panel (10) as defined in claim 1, wherein said first wall elements (26) have a height substantially the same as said first height.
The panel (10) as defined in claim 1, wherein each of said compartments (24) is further subdivided into a plurality of subcompartments (34) defined by a plurality of second wall elements (32), each of said second wall elements (32) extending between one of said first wall elements (26) and one of said sleeves (28, 30).
The panel (10) as defined in claim 9, comprising a plurality of guide tubes (36), wherein each of said guide tubes (36) is located within one of said subcompartments (34).
The panel (10) as defined in claim 10, comprising a plurality of spaced-apart apertures (22) extending through said panel (10) between said first and second sides (14, 16), wherein each of said guide tubes (36) is aligned with one of said apertures (22).
The panel (10) as defined in claim 11, wherein each of said guide tubes (36) further comprises a support rib (38) connecting said tube (36) to a corresponding one of said sleeves (28, 30).
The panel (10) as defined in claim 1, wherein at least some of said first wall elements (26) comprise notches (44) located at positions where said at least some wall elements (26) intersect with other wall elements (26).
The panel (10) as defined in claim 13, wherein said notches (46) are linearly aligned.
The panel (10) as defined in claim 14, wherein each of said notches (44) has a semi-circular profile.
A construction assembly (12) comprising at least two construction panels (10) as defined in any one of claims 1 to 15 coupled together, wherein said second side (16) of one of said panels (10) releasably engages said second side (16) of another one of said panels (10).
The assembly (12) as defined in claim 16, wherein said assembly (12) comprises a first group of said panels (10) arranged adjacent one another with said first and second sides (14, 16) in alignment and a second group of said panels (10) arranged adjacent one another with said first and second sides (14, 16) in alignment, wherein said second sides (16) of said first group of panels (10) engage said second sides (16) of said second group of panels (10), wherein at least some of said panels (10) in said second group overlap multiple panels (10) in said first group to connect said multiple panels (10) together.
The assembly (12) as defined in claim 16, wherein each of said panels (10) comprises linearly aligned notches (44) as defined in claim 14, wherein said linearly aligned notches (44) of one of said panels (10) are aligned with said linearly aligned notches (44) of another one of said panels (10) to together define elongated conduits (46) extending through the interior of said assembly (12).
The assembly (12) as defined in claim 18, wherein each of said notches (44) is semi-circular and wherein each of said conduits (46) is generally cylindrical in profile.
The assembly (12) as defined in claim 19, comprising a fluid delivery tube (48) insertable in a corresponding one of said conduits (46).
The assembly (12) as defined in claim 20, wherein said fluid delivery tube (48) extends either longitudinally or transversely within said assembly (12) between said panels (10).